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SME Annual Meeting

Feb. 25 - 28, 2018, Minneapolis, MN

Preprint 18-023

A FORWARD LOOK INTO THE U.S. RARE EARTHS INDUSTRY; HOW POTENTIAL MINES CAN CONNECT TO THE GLOBAL
REE MARKET

G. Barakos, TU Bergakademie Freiberg, Freiberg, Germany


H. Mischo, TU Bergakademie Freiberg, Freiberg, Germany
J. Gutzmer, Helmholtz Inst. Freiberg for Resource Tech., Freiberg, Germany

ABSTRACT seems to be the most important factor, as it is technically challenging


and expensive to build and to operate.
Mining used to be a business primarily focused on the technical
aspects of getting valuable ore out of the ground and extracting the Thus, in this paper an analysis is made to identify the boundary
minerals efficiently. Without denying the importance of these skills, a conditions that govern both the global and domestic (U.S.) REE
narrow focus on technical issues is no longer enough to guarantee industry in order to determine the factors and establish a market
success when it comes to exploiting rare earth element (REE) channel that can connect potential U.S. REE projects to the global
deposits. Molycorp failed to enter the global REE market in a market.
successful manner, while none of the many REE exploration projects
has turned into an active mine so far and none is expected to A U.S. REE INDUSTRY RETROSPECTIVE
commence operations in the near future. Accordingly, the world of REE The exploration boom in the U.S. resulted in finding several REE
is far more complex compared to other commodities. deposits (Figure 1); while Molycorp began to re-evaluate the REE
This paper looks into the REE industry to identify the factors that project in Mountain Pass, California with a view to bring the mine back
can connect potential U.S. REE mines to the market. The ability to into production.
break free from past thinking and become future-focused is a key
driver. Mining of REE is pointless without a corresponding value-
adding chain, while developing a value chain without first establishing
an uninterruptible source of REE is also senseless. The mining sector
must be based on the REE value chain and vice versa, along with the
establishment of a market channel for the REE products that come out
of the mine.
INTRODUCTION
It has been seven years since rare earth elements became the
subjects of front-page headlines. It was when the controversial
Chinese export policy for these critical commodities was epitomised in
a maritime border dispute with Japan in September 2010 that resulted
in the big REE crisis and price spike of 2011 (Barakos et al, 2016c;
Mancheri, 2015).
The world was dismayed, especially in REE-importing countries,
such as the United States that was and is still totally dependent on Figure 1. The map of U.S. showing the domestic distribution of REE
Chinese production and exports (Barakos et al, 2016c; Kennedy, mines and deposits.
2015). The short-lived alarm initiated a treasure hunt by way of
exploration for REE deposits all over the world. The continuously Prior to the rise of REE mining in China, the United States
growing demand on the one hand and the Chinese sovereignty of the dominated the global market. Mountain Pass initiated operations in
REE-market on the other, led the rest of the world to explore their own 1965 and was the leading producer worldwide for decades, with the
REE resources. In just a few years, more than 400 projects were next-largest producer, Australia, producing only a fraction of the U.S.
initiated to explore REE deposits outside of China (ERECON, 2015; output (Barakos, 2017). However, mining activities stopped in 1998,
Goodenough, 2016). mainly due to the competition from China as well as in response to
environmental issues in the surrounding area of Mountain Pass (Ali,
The prices of REE, however, dropped rapidly and at the moment 2014; Mancheri, 2015).
of writing this paper are in 6-year lows, at the level of the price average
before the 2011 crisis (Barakos, 2017). The viability of even major Molycorp re-activated the mine in 2010 and committed to an
established producers is being challenged, not to mention the expansion, which costed US$ 1.6 billion in order to upgrade its
development prospects of potential REE-market entrants (Barakos et processing and separation facilities (Roskill, 2015). Pressed by
al, 2016b; Rollat et al, 2016). Production cutbacks and industry declining prices for its products, however, Molycorp was forced to
consolidation in China impel REE market experts to forecast that share capital increases and several investors entered the jointed
prices have already reached their lowest point and have nowhere to go venture. Despite the recapitalisations, Molycorp could not avoid filing
but up (Adamas, 2015; Roskill 2015). Yet, expectations for increased for bankruptcy in 2015 loaded with US$ 1.7 billion in debt (Barakos et
REE prices are limited and drastic changes are unlikely to happen in al, 2016b; Machacek & Kalvig, 2016). On its way out of bankruptcy,
the near future, as there is still excess supply in the overall REE Molycorp decided in early-2016 to abandon its Mountain Pass mining
market (Barakos, 2017). facility. The company tried to rebuild itself around the Neo Material line
of businesses that process rare earths, while the Mountain Pass mine
Nevertheless, the low prices of rare earths are not the only reason was separately purchased by MP Mine Operations LLC on July 2017
that potential producers are struggling to enter the global REE market. (Roskill, 2017).
Among other parameters, the separation of the individual elements
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SME Annual Meeting
Feb. 25 - 28, 2018, Minneapolis, MN

Apart from Mountain Pass, significant exploration projects in the connection perspectives of future U.S. REE mines to the global rare
United States include the Bear Lodge, the Bokan-Dotson Ridge, the earths market.
Round Top and the La Paz project. The aforementioned projects are
listed in the TMR Index (www.techmetalsresearch.com) as being in an REE prices
advanced exploration and/or evaluation stage. A major challenge for the U.S. REE industry regards the low
prices of the elements. The REE prices soared in response to the
Additionally, some other interesting deposits have attracted implementation of strict export quotas from the Chinese government
interest. Thus, a list of the most important REE sources in the United and to the fear that there will be a supply chain disruption (Barakos,
States is illustrated in Table 1. The numbering of projects is not related 2017). However, when buyers realised that the actual supply to
to their significance; it starts from west to east and from north to south. consumers was not that tight, prices plunged. The disruption in supply
was also short-lived and the demand for rare earths barely exceeded
The Bokan-Dotson Ridge REE project in Alaska deals with the supply in 2010 and 2011 (Roskill, 2015).
largest HREE deposit in the U.S. and is currently in the evaluation
stage. UCORE Rare Metals owns the project and intends to produce Despite lasting for a short period of time, the high prices of REE
separated and purified rare earth oxides (REO) using Molecular enticed investments in small exploration companies in the U.S. and
Recognition Technology (MRT) (Izatt et al, 2016). around the world, which in turn promised to develop new sources of
rare earths. Nonetheless, mining does not react as quickly to market
The Bear Lodge LREE deposit in Wyoming is being explored by demands; in fact it takes a few years to advance from the exploration
Rare Element Resources. The mineralisation is LREE dominated, like stage to the actual initiation of mining operations. Surprisingly, this was
in Mountain Pass (Roskill, 2015). The project is at an advanced stage; to the benefit of many potential REE producers, since the drop in
an updated pre-feasibility study was published in 2014. prices led to second thoughts and a re-evaluation of the prospects of
Table 1. REE mining and exploration projects in the U.S. their projects. This situation, however, has a profound impact on the
REE project Ownership potential of junior companies to secure investments for capital costs
1 Mountain Pass MP Mine Operations required to work towards mine development (Paulick & Machacek,
2017)
2 Bokan Dotson Ridge UCORE Rare Metals
3 Thor Elissa Resources The steadily low prices of REE in the last two years until the
4 Lemhi Pass U.S. Rare Earths moment of writing this paper indicate that price developments are not
5 La Paz AusAmerican Mining necessarily linked exclusively to changes in supply and demand.
6 Diamond Creek U.S. Rare Earths Through its monopolistic control over the small and opaque REE
7 Bear Lodge Rare Element Resources market, China has managed to reduce the prices at a level that is low
8 Round Top Mountain Texas Mineral Resources enough to prevent other potential producers from commencing mining
9 Elk Creek NioCorp Developments operations. However, there are also indications that the potential of
10 Pea Ridge Wings Enterprises China to influence REE prices is now also limited; the prices have
dropped so low that even the viability of Chinese REE projects is at
The Round Top REE deposit is another very large, yet low grade risk. Illegal mining and processing of rare earths inside China and their
resource worth mentioning. The project is located at Round Top smuggling out of the country is destroying the Chinese REE industry,
Mountain, Texas and is enriched in both LREE and HREE as well as in while only the downstream industries are profitable at the expense of
other elements such as lithium, beryllium, thorium, uranium, niobium, the environment (Packey & Kingsnorth, 2016).
tantalum and hafnium (Roskill, 2015). In an effort to detain illegal depletion of domestic resources at the
The La Paz REE deposit is a low grade LREE source located in expense of the environment, Chinese authorities have been
Arizona AusAmerican Mining Corporation owns and runs the La Paz consolidating the domestic REE industry into big government-
REE exploration project that is still under preliminary evaluation. controlled enterprise groups (Roskill, 2015). Nonetheless, as long as
illegal production of REE finds customers both inside and out of China,
Other remarkable REE sources that have not been translated yet the prices of the elements will stay in alarmingly low levels.
into advanced exploration projects include the Thor REE deposit in
New York Mountains, Nevada; the Lemhi Pass and Diamond Creek The balance problem
sources in Idaho; the Elk Creek project in Nebraska; and the Pea But even if the REE prices were high enough to allow potential
Ridge REE project in St. Louis, Missouri (Roskill, 2015). producers initiate operations, there would still be important issues that
would jeopardize the long-term viability of their projects.
According to the United States Geological Survey (USGS) the
global estimated reserves of rare earths are rounded at 120 Mt, while An obvious reason for possible failure is the oversupply of REE in
the domestic reserves in the U.S. are calculated at 1.4 Mt (USGS, their relatively small market. The global consumption is of the order of
2017). It should be mentioned here that the reserves estimate for 2015 150,000 tonnes per annum (USGS, 2017) and any additional
was 4.1Mt, whereas the estimate for 2010 was 13Mt (Paulick & production of rare earths would cause a glut in the marketplace. A
Machacek, 2017). This reduction is attributed to the reclassification of reasonable argument could arise at this point. Since new sources of
historic resources at Mountain Pass using the more stringent REE are now available outside of China, it would be a good
requirement of NI 43-101 reporting. opportunity to change the current situation so that worldwide
consumers stop buying from China, thus allowing new producers to
CHALLENGES FOR THE U.S. REE INDUSTRY obtain that significant share of the market. Nevertheless, the rationale
behind this argument is not that simple.
Without doubt, the U.S. is home to a significant amount of REE
resources and theoretically there could be a supply of rare earths for The group of REE consists 15 different elements with interesting
several years. Nevertheless, the country is 100% import-reliant on similarities but at the same time extremely different characteristics and
REE and thus, the exploitation of U.S. domestic resources seems to be behaviors. Their diversity in physical and chemical properties defines
offering no real solution to the problem. The emphatic failure of their individual demand in different applications and in turn their
Molycorp to run Mountain Pass in a successful manner is the most criticality. In addition to this, REE are not present in equal amounts in
typical example (Barakos et al, 2016b; Kennedy, 2015). their host minerals. REE-bearing minerals generally contain most of
the rare earths in varying concentrations, but tend to be biased
The REE industry is not a simple explore-extract-merchandise towards either LREE or HREE. In general terms, light REE are
business; it is governed by a set of special boundary conditions which substantially more abundant in REE deposits than the heavy REE.
can determine the feasibility of any potential REE mining project.
These conditions are discussed hereinafter in order to evaluate the Apparently, it is not possible to selectively target just one specific
element of the REE group for mining. All REE have to be mined

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SME Annual Meeting
Feb. 25 - 28, 2018, Minneapolis, MN

together and get separated through various metallurgical procedures. On the other hand, the processing potentials of rare earths
Hence, if the elements in higher demand have a lower abundance outside of China are limited with respect to the separation of LREE and
within these geological formations, the minimum quantity that needs to none concerning to the separation of HREE (Barakos, 2017; Machacek
be mined, processed and separated must be at least the amount & Fold, 2014). The Lynas Advanced Materials Plant (LAMP) in
required for these critical applications (Binnermans & Jones, 2015). As Malaysia is currently the most advanced facility in the world for
a consequence, elements of higher abundance and lower criticality will producing a mixed rare earth oxide concentrate that is free of any
be produced in larger than required quantities, and due to these impurities and hazardous elements (e.g. naturally occurring radioactive
surpluses, they will have to be stockpiled, thus increasing the costs of materials - NORMs).
mining, processing and storing. This is the reason why for the time
being cerium and lanthanum sell below cost (Kennedy, 2015). When it comes to the chemical separation of the individual REO,
it can be accomplished by only a handful of companies outside of
That being the case, the deposit in Mountain Pass is rich in non- China. There are three European-based firms, namely Rhodia in
critical LREE (mainly lanthanum and cerium) and this has factually France (also known as Rhône-Poulenc, and which is now part of
played a major role in its current economic status. Apparently there is Belgian Solvay and supplying technology to Lynas), Silmet in Estonia
already a surplus in the global market of the LREE that Molycorp had (which is owned by Molycorp) and the British company Less Common
been producing. As if this is not enough, expanding the production of Metals. Additionally, there are a few Japanese companies such as
these specific elements may gradually affect market prices for all the Hitachi Metals, Santoku, Showa Denko K. K., Shin-Etsu Chemical and
other non-critical rare earths. For instance, an increase in supply by Nippon Yttrium (Barakos, 2017; Roskill, 2015).
REE-separating companies in mid-2014 resulted in prices descending
further, especially for dysprosium, praseodymium and neodymium In the U.S. there are no active REE processing facilities.
oxides (Barakos, 2017; Mancheri, 2015) Following the failure of Molycorp to establish a processing plant in
Mountain Pass, UCORE is the only company that has entered into an
But even if the production in Mountain Pass would have included agreement with IBC Advanced Technologies Inc. to develop a
large volumes of high-valued REE, the only way for Molycorp and for metallurgical processing method for the separation and purification of
any other potential REE producer to sell the total amount of their the REE coming out of the Bokan Dotson Ridge potential mine in
planned production would be by marketing into China that is the main Alaska. Through a customised SuperLig® hydrometallurgical process
global consumer of rare earths. This would place the companies in at bench scale with the use of Molecular Recognition Technology, IBC
direct competition with a mature Chinese mining and processing sector successfully separated the entire suite of individual REE at high purity
with significantly lower costs and thus far lower prices (ERECON, >99% (Izatt et al, 2016). The application of MRT is presented by Ucore
2015). as a revolutionary clean chemistry alternative to the more costly,
slower and environmentally invasive solvent extraction based methods
The broken REE supply chain of REE separation. So far, however, the company has provided no
But neither the overall costs nor the low prices are the real information regarding either the costs or the potential environmental
problem facing the United States among other non-Chinese industrial impacts associated with the use of MRT. Hence, at the time of writing
nations. The actual problem is the absence of a robust and fully this paper, no safe conclusions can be drawn for the efficiency of this
integrated value chain with sufficient capacity to translate the ore processing method.
coming out of a REE mine into valuable end-products such as smart
phones, wind turbines and electronic components for defence systems. By taking these facts into account it is easily understandable why
consumers prefer to be supplied by China and not from standalone
This vertical integration consists not only the mining and primary mining companies who cannot replicate a complex REE value chain.
beneficiation of REE -which are likely the easy steps to take- but also To further highlight the significance of this issue, it must be pointed out
the separation and purification of the individual REO and their refining that before its bankruptcy Molycorp was shipping all of its non-cerium
to meet specific downstream technology applications (Figure 2). Seven and lanthanum oxides to China for refining into high-value metals,
years after the REE crisis, it is now common ground that the alloys and then into valuable end-products with all that this situation
separation of the individual elements is the most fundamental part of implies (Kennedy, 2015).
the overall supply chain, since it is both technically challenging and
expensive to build and operate. Environmental impacts and legislation issues
On top of the aforementioned, the REE industry is characterised
by another drawback, namely environmental impacts. Gaining the
necessary permits to run a mine including the “social licence to
operate” is a challenge for all mining operations but is a particular
difficulty for REE producers if ores contain NORMs and if they will
produce radioactive waste. Waste disposal areas are exposed to
weathering conditions and have the potential to pollute the air, soil and
water if adequate monitoring and protection measures are not utilized
(Barakos et al, 2015). In addition to the presence of radioactivity, the
use of dangerous chemicals and toxic compounds during the
processing of REE can also result in negative environmental effects.
Lax compliance with the regulations has resulted in environmental
consequences and illegal mining in China (Ali 2014), while overly strict
environmental regulations forced REE mining operations in Mountain
Pass to stop in the first place (Barakos, 2017). The Chinese legacy of
environmental damage due to REE mining and processing activities
has raised social concerns and caused hesitation against any REE
production activities elsewhere.
Figure 2. The rare earth element supply chain (Barakos, 2017).
Nevertheless, the pressure to take action on REE had quickly
China is currently the only country that has developed this swelled in Congress, the Defence Department, the Department of
complete value adding chain - comprising of numerous independent Energy and elsewhere across the U.S. government. In the recent
companies dedicated to REE research and production, each providing years, a series of bills were introduced to the Congress. Among the
highly differentiated technologies, processing, formulation, or most important legislation enactments were the H.R. 4883 and S. 2006
component-specific applications. bills that introduced the establishment of a National Rare Earth
Refinery Cooperative to provide for the domestic processing of
thorium-bearing REE concentrates (Barakos et al, 2016a).
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SME Annual Meeting
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CONNECTING POTENTIAL MINES TO THE REE MARKET possibly even “switch-on, switch-off” supplies that could react quickly
to changes in demand and to the fluctuation of REE prices.
Based on the above, the status quo of the REE market and
industry do not allow for potential producers to initiate their projects in Stakeholders from the U.S. coal industry hope to re-purpose old
the foreseen future. Nevertheless, these discussions are deemed mines to produce REE, while recent research in the United States
necessary not only for preventing potential projects from failure but points out that the size and concentration of HREE as by products in
also for determining which, if any, are the connection perspectives of some unmined U.S. phosphorites predominates over the world's
U.S. potential REE projects to the domestic and global market. richest REE deposits (Barakos et al, 2016b).
Policies and strategies Regulations and legislation instruments
To begin with, a change of policy is necessary now more than The enactment of direct and effective legislation instruments in
ever. China can hardly be blamed for its clever use of global mineral the U.S. has been an optimistic step towards a more robust and
resources. Prior to the rise of REE mining in China, the United States efficient REE supply chain. Yet, there is more that needs to be done. In
dominated the world scene for decades but the unsustainable U.S. the context of establishing a cooperative for the domestic REE
mineral resource policies during the last 30 years have contributed industry, further regulations must be issued.
mightily to the present state of dependence.
No mining or processing licence should be granted if there is an
Relying on export streams from China became easier and insufficient mining site remediation plan followed by a waste disposal
economically more feasible. However, stakeholders ought to think and management project as well. The Chinese pollution problem due
about short term versus long term. The decision to sit on the sidelines to lax legislation that is now costing China billions of dollars to correct
may work in a nearsighted scenario, but when a single entity has a is to be avoided at any cost.
near monopoly such a move will no doubt become less than desirable
as time passes. However, due to the current regulations on extracting and storing
NORMs, many mines dump material containing REE with the rest of
China is not anymore mining REE for a source of income and their waste products, despite the high value of such material (Kennedy,
political clout but first and foremost for its own benefit; its growing 2015). Thus the foundation of a corporation with the express purpose
population is consuming REE at an astonishing rate. This is why China of extracting and storing radioactive materials like thorium could result
is trying not only to control the depletion of own resources, but also in having additional REE sources without the cost of mining them.
seeks to invest in foreign exploration REE projects. In the recent past
China has been close enough to take control of some of the most It should be noted here, that REE do not harm the environment,
significant REE sources in the rest of the world, including Mount Weld bad practices do. Under modern technologies the mining and
in Australia and Mountain Pass in California. processing of REE might be just as good or bad as in any other mining
industry sector (Barakos, 2017). Hence, local societies also need to be
The latter was eventually sold in July 2017 to a Chinese-led informed about the significance of REE production in order for the REE
consortium and it is likely that Beijing will have an influence over the mining companies to obtain the social license to operate.
development and direction of Mountain Pass. Similarly to other REE
projects in the U.S. and around the world, the restart of production at Marketability of REE mine products
Mountain Pass in the short term remains unlikely. The entire above are steps to be taken in the right direction, but
are not the most determining factors that will connect a potential U.S.
A suggestion could be that the United States should play a REE mine to the market. Given the size of the market, only a few of the
waiting game and simply allow for reserves in China to be exhausted exploration projects will actually become REE mines over the next
(Paulick & Machacek, 2017). Such a mindset, however, is troubling, decade; which ones go into production is also difficult to predict. The
since it would place an additional delay on the time it would take to only sure thing is that the different demand for the individual REE will
ready a potential REE mine site or build a processing plant for the full play an important role.
separation of rare earths. In addition to this, the Chinese expansionary
policy will keep on luring junior projects from all over the world to ship The demand pattern for REE has changed in recent years with a
their products to China for further processing and fabrication. tilt towards higher use of HREE (Paulick & Machacek, 2017). Demand
is driven by the expansive interest in renewable and more efficient
China was able to establish an integrated value adding chain of energy technologies, which rely, among other, on the magnetic and
REE, but it has taken decades to achieve current capacities and fluorescent properties of HREE.
capabilities and Chinese producers have been careful to keep this
technology secret. Hence, such a technology cannot be duplicated in Consequently, the development prospects of LREE suppliers like
the short term and that is something that the Western world has to Mountain Pass seem to be low; only a few of the mines that can
realize and act accordingly. produce high-in-demand and commercially recoverable HREE may
start operations.
It will take time and a lot of effort to catch up with China, let alone
the fact that the cost of creating a large-scale fully integrated value Nevertheless, the Chinese involvement in Mountain Pass may be
chain exceeds the financial capacity of any one company, industry or a positive, given the processing expertise which Shenghe Resource
even nation. In such cases, the U.S. has historically used cooperatives that is leading the consortium can bring to the project and its
to overcome market failures by spreading financial risk, gaining access experience of marketing rare earth products. On the other hand,
to low-cost capital, and expanding market access, thus ensuring the among the HREE-oriented U.S. REE potential projects, Bokan
production and lowering the cost for critical resources (Kennedy, Mountain seems to be having some potential. However, until the MRT
2015). proves to be a feasible REE separation method the perspectives of this
project will remain uncertain.
A cooperative would enable end users to act together and procure
finished REE products that currently are available only from China. As if this is not enough, potential REE producers must carefully
This value chain could provide a market for the U.S. REE resources, assess which of their products can be sold entirely and which will be
without being undercut by the Chinese monopoly. stockpiled. For instance, elements such as holmium, erbium, thulium,
ytterbium and lutetium, despite being classified as HREE have limited
Initially, however, the low REE prices and the elevated costs will to no marketability and should not be considered in the REE basket
still be a deterrent factor for new REE projects even in a cooperative. price calculations. The marketability of REE included in the deposit is,
Thus, projects that can start with a low capital expenditure, and then therefore, significant.
run at low cost, may have a distinct advantage. Furthermore, the
extraction of REE as co- or by-products from existing mines is The existence of negotiations and/or agreements with potential
potentially an attractive way to bring new supplies rapidly on stream, customers is critical and can determine the REE basket price and
marketing policy of the mining company. Having a fixed long-term

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SME Annual Meeting
Feb. 25 - 28, 2018, Minneapolis, MN

pricing deck on customer-specified products (either oxides or mix 7. Barakos, G. (2017), “An assessment tool for the mineability of
concentrates) will define the feasibility prospects of the REE project in rare earth element deposits”, PhD Diss., Technical University
a more secure manner. Bergakademie Freiberg, Germany.
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